Download Craftsman 944.365440 Owner`s manual
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Owner's Manual JCRAFTSMIIN' owE R ROTARY LAWN 5.5 Horsepower 21" Multi-Cut Model No. 944.365440 CAUTION: Read and follow all Safety Rules and Instructions beforeoperatingthis equipment Sears Canada, Inc., Toronto, Ontario M5B 2B8 Warranty .................................................. 2 Safety Rules ......................................... 2-4 Product Specifications ........................... 4 Assembly/P re-Operation ......................... 5 Operation .............................................. 6-9 Maintenance Schedule .......................... 10 Maintenance ..................................... Service and Adjustments .................. Storage ............................................. Troubleshooting ................................ Repair Parts ...................................... Sears Service .......................... Back 10-13 13-14 14-15 15-16 18-23 Cover LIMITED TWO YEAR WARRANTY ON CRAFTSMAN POWER MOWER For two years from date of purchase Sears Canada, Inc. will repair or replace at Sears option free of charge parts which are defective as a result of material or workmanship. COMMERCIAL OR RENTAL USE: Warranty on Power Mower (Gas) will be ninety (90) days from date of purchase if used for commercial or rental purposes. This Warranty does NOT cover: • Pre-delivery set-up. • Expendable items which become worn during normal use, such as rotary mower blades, blade adapters, belts, air cleaners and spark plug. • Repairs necessary because of operator abuse or negligence, including bent crankshafts and the failure to maintain the equipment according to the instructions contained in the owner's manual. Warranty service is available by returning the Craftsman Power Mower to the nearest Sears Service Centre/Department in Canada. This warranty applies only while this product is used in Canada. This warranty is in addition to any statutory warranty and does not exclude or limit legal rights you may have but shall run concurrently with applicable provincial legislation. Furthermore, some provinces do NOT allow limitation on how long an implied warranty will last so the above limitations may not apply to you. Sears Canada, Inc., Toronto, Ontario M5B 2B8 IMPORTANT: This cutting machine iscapable of amputating hands and feet and throwing obj ects. Failure to observe the following safety instructions could result in serious injury or death. _Look for this symbol to point out imI. GENERAL OPERATION portant safety precautions. It means • Read, understand, and follow all CAUTION!!! BECOME ALERT!!! instructions on the machine and in the YOUR SAFETY IS INVOLVED. manual(s) before starting. Be thoroughly AWARNING: In order to prevent acfamiliar with the controls and the proper cidental starting when setting up, transuse of the machine before starting. porting, adjusting or making repairs, • Do not put hands or feet near or under always disconnect spark plug wire and rotating parts. Keep clear of the displace wire where it cannot come in contact charge opening at all times. with plug. • Only allow responsible individuals, who A CAUTION: Muffler and other engine are familiar with the instructions, to parts become extremely hot during operate the machine. operation and remain hot after engine has • Clear the area of objects such as rocks, stopped. To avoid severe burns on contact, toys, wire, bones, sticks, etc., which could be picked up and thrown by blade. stay away from these areas. • Be sure the area is clear of other people before mowing. Stop machine if anyone enters the area. • Do not operate the mower when barefoot or wearing open sandals. Always 2 wear substantial foot wear. • Do not pull mower backwards unless • • • • • • • • • • • • • Do not trim excessively steep slopes. • Do not mow on wet grass. Reduced footing could cause slipping. absolutely necessary. Always look down and behind before and while moving backwards. Never direct discharged material toward anyone. Avoid discharging material against a wall or obstruction. Material may richochet back toward the operator. Stop the blade when crossing gravel surfaces. Do not operate the mower without proper guards, plates, grass catcher or other safety protective devices in place. See manufacturer's instructions for proper operation and installation of accessories. Only use accessories approved by the manufacturer. Stop the blade(s) when crossing gravel drives, walks, or roads. Stop the engine (motor) whenever you leave the equipment, before cleaning the mower or unclogging the chute. Shut the engine (motor) off and wait until the blade comes to complete stop before removing grass catcher. Mow only in daylight or good artificial light. Do not operate the machine while under the influence of alcohol or drugs. Never operate machine in wet grass. Always be sure of your footing: keep a firm hold on the handle; walk, never run. Disengage the self-propelled mechanism or drive clutch on mowers so equipped before starting the engine. If the equipment should start to vibrate abnormally, stop the engine (motor) and check immediately for the cause. Vibration is generally a warning of trouble. Always wear safety goggles or safety glasses with side shields when operating mower. II. SLOPE III. CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Neverassume that children will remain where you last saw them. • Keep children out of the trimming area and under the watchful care of another responsible adult. • Be alert and turn machine off if children enter the area. • Before and while walking backwards, look behind and down for small children. • Never allow children to operate the machine. • Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. IV, SAFE OF GASOLINE Use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. • Extinguish all cigarettes, cigars, pipes and other sources of ignition. • Use only an approved container. • Never remove gas cap or add fuel with the engine running. Allow engine to cool before refueling. • Never refuel the machine indoors. • Never store the machine or fuel container where there is an open flame, spark or pilot light such as a water heater or on other appliances. • Never fill containers inside a vehicle, on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling. • Remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a gasoline dispenser nozzle. • Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device. • If fuel is spilled on clothing, change clothing immediately. • Never overfill fuel tank. Replace gas cap and tighten securely. OPERATION Slopes are a major factor related to slip & fall accidents which can result in severe injury. All slopes require extra caution. If you feel uneasy on a slope, do not mow it. DO: • Mow across the face of slopes: never up and down. Exercise extreme caution when changing direction on slopes. • Remove obstacles such as rocks, tree limbs, etc. • Watch for holes, ruts, or bumps.Tall grass can hide obstacles. DO NOT: • Do not trim near drop-offs, ditches or embankments. The operator could lose footing or balance. HANDLING 3 V. GENERAL SERVICE • Never run machine inside a closed area. • Never make adjustments or repairs with the engine (motor) running. Disconnectthe spark plug wire, and keep the wire away from the plug to prevent accidental starting. • Keep nuts and bolts, especially blade attachment bolts, tight and keep equipment in good condition. • Never tamper with safety devices. Check their proper operation regularly. • Keep machine free of grass, leaves, or other debris build-up. Clean oil orfuel spillage. Allow machine to cool before storing. • Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting. • Never attempt to make wheel height adjustments while the engine is running. • Grass catcher components are subject to wear, damage, and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer's recommended parts, when necessary. • Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing them. • Do not change the engine governor setting or overspeed the engine. • Maintain or replace safety and instruction labels, as necessary. AWARNING: This lawn mower is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brush-covered or grass-covered land unless the engine's exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any), If a spark arrester is used, it should be maintained in effective working order by the operator. A spark arrester for the muffler is available through your nearest Sears Service Centre (See the REPAIR PARTS section of this manual). Serial Number: Date of Purchase: Gasoline Capacity /Type: 0,94 Litres (Unleaded Regular) Oil Capacity: 0,5 Litres Oil Type (API SG-SL): SAE 30 (above 0°C/32°F) Spark Plug (Gap: 0,76 ram) NGK BPR6ES Valve Clearance (± 0.04 ram): Intake: 0.015 mm; Exhaust: 0.020 mm Blade Bolt Torque: 35-40 ft. Ibs. (47-54 N-m) or SAE 10W-30 The model and serial numbers will be found on a decal on the rear of the lawn mower housing. Record both serial number and date of purchase in space provided above. 4 Read these instructions and this manual in its entirety before you attempt to assemble or operate your new lawn mower. IMPORTANT: This lawn mower is shipped WITHOUT OIL OR GASOLINE in the engine. Your new lawn mower has been assembled at the factory with the exception of those parts left unassembled for shipping purposes. All parts such as nuts, washers, bolts, etc., necessary to complete the assembly have been placed in the parts bag. To ensure safe and proper operation of your lawn mower, all parts and hardware you assemble must be tightened securely. Use the correct tools as necessary to ensure proper tightness. TO REMOVE CARTON MOWER Operator control bar Handle knob Lower handle FROM TO ASSEMBLE GRASS CATCHER 1. Put grass catcher frame into grass bag with rigid part of bag on the bottom. Make sure the frame handle is outside of the bag top. 2. Slip vinyl bindings over frame. NOTE: If vinyl bindings are too stiff, hold them in warm water for a few minutes. If bag gets wet, let it dry before using. Cut down two end corners of carton and lay end panel down flat. 3. Remove all packing materials except padding between upper and lower handle and padding holding operator presence control bar to upper handle. 4. Roll mower out of carton and check carton thoroughly for additional loose parts. HOWTO SET UPYOUR TO UNFOLD HANDLE Upper handle uP 1. Remove loose parts included with mower. 2. MOWING POSITION _ame MOWER IMPORTANT: Unfold handle carefully so as not to pinch or damage control cables. 1. Raise handles until lower handle section locks into place in mowing position. 2. Remove protective padding, raise upper handle section into place on lower handle and tighten both handle knobs. 3. Remove handle padding holding operator presence control bar to upper handle. Your lawn mower handle can be adjusted for your mowing comfort. Refer to "ADJUST HANDLE" in the Service and Adjustments section of this manual. Vinyl bindings Frame opening TO INSTALL ATTACHMENTS Your lawn mower was shipped ready to be used as a mulcher. To convert to bagging, see "TO CONVERT MOWER" in the Operation section of this manual 5 KNOW YOUR LAWN MOWER READTHIS OWNER'S MANUAL AND ALL SAFETY RULES BEFORE OPERATINGYOUR LAWN MOWER, Compare the illustrations with your lawn mower to familiarize yourself with the location of various controls and adjustments. Save this manual for future reference. These symbols may appear on your lawn mower or in literature supplied with the product. Learn and understand their meaning. CAUTION ENGINE OR WARNING ON ENGINE OFF FAST SLOW CHOKE FUEL OIL DANGER, KEEP HANDS AND FEET AWAY :Dperator presence control bar =o + ,,=, .= == Starter handle' Gasoline filler cap Grass + ,,=, Fuel valve lever z Air filter Engine oil plug Housing Muffler Mulcher door Spark plug IMPORTANT: This lawn mower is shipped WITHOUT OIL OR GASOLINE in the engine. Wheel adjuster (on each wheel) MEETS CPSC SAFETY REQUIREMENTS Sears rotary walk-behind power lawn mowers conform to the safety standards of the American National Standards Institute and the U.S. Consumer Product Safety Commission. The blade turns when the engine is running. Operator presence control bar - must be held down to the handle to start the engine. Release to stop the engine, 6 Mulcher door - allows conversion to discharging or bagging operation. Starter handle - used for starting engine. The operation of any lawn mower can result in foreign objects thrown into the eyes, which can result in severe eye damage. Always wear safety glasses or eye shields while operating your lawn mower or performing any adjustments or repairs. We recommend standard safety glasses or a wide vision safety mask worn over spectacles. HOWTO REAR BAGGING • Lift rear door of the lawn mower and place the grass catcher frame hooks onto the door pivot pins. • To convert to mulching or discharging operation, remove grass catcher and close rear door. Pivot pins Rear Grass catcher handle USI= YOUR LAWN MOWER ENGINE SPEED The engine speed was set at the factory for optimum performance. Speed is not adjustable. ENGINE ZONE CONTROL _I=CAUTION: Federal regulations require an engine control to be installed on this lawn mower in order to minimize the risk of blade contact injury. Do not under any circumstances attempt to defeat the function of the operator control. The blade turns when the engine is running. • Your lawn mower is equipped with an operator presence control bar which requires the operator to be positioned behind the lawn mower handle to start and operate the lawn mower. Catcher frame hook SIDE DISCHARGING • Rear door must be closed. • Open mulcher door and install discharge deflector under door as shown. • Mower is now ready for discharging operation. • To convert to mulching or bagging operation, discharge deflector must be removed and mulcher door must be closed. TO ADJUST CUTTING HEIGHT Raise wheels for low cut and lower wheels for high cut, adjust cutting height to suit your requirements. Medium position is best for most lawns. • To change cutting height, squeeze adjuster lever toward wheel. Move wheel up or down to suit your requirements. Be sure all wheels are in the same setting. NOTE: Adjuster is properly positioned when plate tab inserts into hole in lever. Also, 9-position adjusters (if so equipped) allow lever to be positioned between the plate tabs. Open mulcherdoor LEVER BACKWARD TO LOWER MOWER LEVER FORWARD TO RAISE MOWER TO CONVERT Lever MOWER Your lawn mower was shipped ready to be used as a mulcher. To convert to bagging or discharging: 7 Discharge deflector _1_CAUTION: DO NOT overfill engine with oil, or it will smoke on startup. 1. Be sure lawnmower is level. 2. Remove oil dipstick from oil fill spout. 3. You recieve a container of oil with the unit. Slowly pour the entire container down the oil fill spout into the engine. 4. Insert and tighten dipstick. IMPORTANT: • Check oil level before each use. Add oil if needed. Fill to full line on dipstick. • Change the oil after every 25 hours of operation or each season. You may need to change the oil more often under dusty, dirty conditions. See "TO CHANGE ENGINE Oil" in the Maintenance section of this manual. deflector SIMPLE STEPS TO REMEMBER WHEN CONVERTING YOUR LAWN MOWER FOR MULCHING 1. Rear door closed. 2. Mulcher door closed. FOR REAR BAGGING 1. Grass catcher installed. 2. Mulcher door closed. FOR SIDE DISCHARGING 1. Rear door closed. 2. Discharge deflector installed. _CAUTION: Do not run your lawn mower without rear door closed or approved grass catcher in place. Never attempt to operate the lawn mower with the rear door removed or propped open. TO EMPTY GRASS CATCHER ADD GASOLINE • Fill fuel tank to bottom of tank filler neck. Do not overfill. Use fresh, clean, regular unleaded gasoline with a minimum of 87 octane. Do not mix oil with gasoline. Purchase fuel in quantities that can be used within 30 days to assure fuel freshBESS. • k CAUTION: Wipe off any spilled oil or fuel. Do not store, spill or use gasoline ,_ar an open flame. CAUTION: Alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. Empty the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel next season. See Storage Instructions for additional information. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur. 1. Lift up on grass catcher using the frame handle. 2. Remove grass catcher with clippings from under lawn mower handle. 3. Empty clippings from bag. NOTE: Do not drag the bag when emptying; it will cause unnecessary wear. "_l'k I_,_L_ "_,,,_ "'"--._,_. t_.,_:._) Grass catcher frame Oil fill cap / / - --_ handle BEFORE STARTING ENGINE ADD OIL Your lawnmower is shipped without oil in the engine. For type and grade of oil to use, see "ENGINE" in the Maintenance section of this manual. Upper mark 8 mark Gasoline filler cap TO STOP ENGINE • To stop engine, release operator presence control bar. Wait until blade and all moving parts have stopped and turn fuel valve to OFF position if you do not intend to restart the engine soon. TO START ENGINE NOTE: Due to protective coatings on the engine, a small amount of smoke may be present during the initial use of the product and should be considered normal. 1. Be sure fuel valve is in the ON position. 2. Move choke lever to ON ( N ) position. 3. Hold operator presence control bar down to the handle and pull starter handle quickly. Do not allow starter rope to snap back. NOTE: The choke lever automatically begins moving to the OFF position when operator presence control bar is held down to handle. OFF Fuel valve lever • Pores in cloth grass catchers can become filled with dirt and dust with use and catchers will collect less grass. To prevent this, regularly hose catcher off with water and let dry before using. • Keep top of engine around starter clear and clean of grass clippings and chaff.This will help engine airflow and extend engine life. MULCHING MOWING TIPS IMPORTANT: For best performance, keep mower housing free of built-up grass and trash. See "CLEANING" in the Maintenance section of this manual. • The special mulching blade will recut the grass clippings many times and reduce them in size so that as they fall onto the lawn they will disperse into the grass and not be noticed. Also, the mulched grass will biodegrade quickly to provide nutrients for the lawn. Always mulch with your highest engine (blade) speed as this will provide the best recutting action of the blades. • Avoid cutting your lawn when it is wet. Wet grass tends to form clumps and interferes with the mulching action. The best time to mow your lawn isthe early afternoon. At this time the grass has dried, yet the newly cut area will not be exposed to direct sunlight. • Forbest results, adjustthe lawn mowercutting height so that the lawn mower cuts off only the top one-third of the grass blades. Ifthe lawn is overgrown itwill be necessary to raise the height of cut to reduce pushing effort and to keep from overloading the engine and leaving clumps of mulched grass. For extremely heavy grass, reduce your width of cut by overlapping previously cut path and mow slowly. MOWING TIPS CAUTION: Do not use de-thatcher blade attachments on your mower. Such attachments are hazardous, will damage your mower and could void your warranty. • Under certain conditions, such as very tall grass, it may be necessary to raise • Certain types of grass and grass conditions the height of cut to reduce pushing effort may require that an area be mulched a secand to keep from overloading the engine ond time to completely hide the clippings. and leaving clumps of grass clippings. When doing a second cut, mow across It may also be necessary to reduce (perpendicular) to the first cut path. ground speed and/or run the lawn • Change your cutting pattern from week mower over the area a second time. to week. Mow north to south one week • For extremely heavy cutting, reduce the then change to east to west the next width of cut by overlapping previously week. This will help prevent matting and cut path and mow slowly. graining of the lawn. • For better grass bagging and most cutting conditions, the engine speed should be set in the FAST position. 9 MAINTENANCE SCHEDULE BEFORE EACH USE AFTER EACH USE EVERY 10 HOURS EVERY 25 HOURS OR SEASON EVERY 100 HOURS BEFORE STORAGE Check for Loose Fasteners i Check Tires Clean Inspect Grass*** Catcher * Check / Drive Wheels Clean Lawn Mower .... _ v' Clean under Drive Cover *'* Check Drive Belt / Pulleys "*" _ Check / Sharpen / Replace Blade R Lubrication Clean and Recharge Battery *" Check Engine Oil level E Change Engine Oil mClean Air Filter Inspect Muffler _t Replace v' Spark Plug E Replace Air Filter Paper Cartridge Empty fuel system or add Stabilizer * ** .1,* **** (if so equipped) Electric-Start mowers Power-Propelled mowers Use a scraper to clean underdeck GENERAL 1 2 3 4 5 - Change more often if operating under a heavy load or in high outdoortemperatures. - Service more often it operating in dirty or dusty conditions. - Replace blades more often when mowing in sandy soil. - Charge 48 hours at end of season. - And after each 5 hours of use. LUBRICATION RECOMMENDATIONS CHART The warranty on this lawn mower does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, operator must maintain unit as instructed in this manual, (!) Wheel juster (on ch wheel) Engine oil Some adjustments will need to be made periodically to properly maintain your unit. C) Mulcher ,door hinge pin At least once a season, check to see if you should make any of the adjustments described in the Service and Adjustments section of this manual. • At least once a year, replace the spark plug, clean or replace air filter element and check blade for wear. A new spark plug and clean/new air filter element assure proper air-fuel mixture and help your engine run better and last longer. • Follow the maintenance schedule in this manual. Rear door hinge (_) Handle bracket mounting pins _ BEFORE EACH USE • Check engine oil level. • Check for loose fasteners. LUBRICATION Keep unit well lubricated (See "LUBRICATION CHART"). Spray lubricant See "ENGINE" in Maintenance section. IMPORTANT: Do not oil or grease plastic wheel bearings. Viscous lubricants will attract dust and dirt that will shorten the lifeof the self-lubricating bearings. If you feel they must be lubricated, use only a dry, powdered 10 graphite type lubricant sparingly. LAWN MOWER Always observe safety rules when performing any maintenance. TIRES • Keep tires free of gasoline, oil, or insect control chemicals which can harm rubber. • Avoid stumps, stones, deep ruts, sharp objects and other hazards that may cause tire damage. BLADE CARE For best results, blade must be kept sharp. _eplace a bent or damaged blade. CAUTION: Use only a replacement blade approved by the manufacturer of your mower. Using a blade not approved by the manufacturer of your mower is hazardous, could damage your mower and void your warranty. TO REMOVE BLADE 1. Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug. 2. Turn lawn mower on its side. Make sure air filter and carburetor are up. 3. Use a wood block between blade and mower housing to prevent blade from turning when removing blade bolt. NOTE: Protect your hands with gloves and/or wrap blade with heavy cloth. 4. Remove blade bolt by turning counterclockwise. 5. Remove blade and attaching hardware (bolt, lock washer, hardened washer). NOTE: Remove the blade adapter and check the key inside hub of blade adapter. The key must be in good condition to work properly. Replace adapter if damaged. TO REPLACE BLADE 1. Position the blade adapter on the engine crankshaft. Be sure key in adapter and crankshaft keyway are aligned. 2. Position blade on the blade adapter aligning the two (2) holes in the blade with the raised lugs on the adapter. 3. Be sure the trailing edge of blade (opposite sharp edge) is up toward engine. 4. Install the blade bolt with the lock washer and hardened washer into blade adapter and crankshaft. 5. Use block of wood between blade and lawn mower housing and tighten the blade bolt, turning clockwise. • The recommended tightening torque is 35-40 ft. Ibs. / 47-54 N-m. IMPORTANT: Blade bolt is heat treated. If bolt needs replacing, replace only with approved bolt shown in the Repair Parts section of this manual. Blade adapte Crankshaft keyway Lockwasher Blade Blade bolt H washer Crankshaft TO SHARPEN BLADE NOTE: We do not recommend sharpening blade - but if you do, be sure the blade is balanced. Care should be taken to keep the blade balanced. An unbalanced blade will cause eventual damage to lawn mower or engine. • The blade can be sharpened with a file or on a grinding wheel. Do not attempt to sharpen while on the mower. • To check blade balance, drive a nail into a beam or wall. Leave about one inch of the straight nail exposed. Place center hole of blade over the head of the nail. If blade is balanced, it should remain in a horizontal position. If either end of the blade moves downward, sharpen the heavy end until the blade is balanced. GRASS CATCHER • The grass catcher may be hosed with water, but must be dry when used. • Check your grass catcher often for damage or deterioration. Through normal use it will wear. If catcher needs replacing, replace only with approved replacement catcher shown in the Repair Parts section of this manual. Give the lawn mower model number when ordering. ENGINE Maintenance, repair, or replacement of the emission control devices and systems, which are being done at the customers expense, may be performed by any non-road engine repair establishment or individual. Warranty repairs must be performed by an authorized engine manufacturer's service out]et. LUBRICATION Use only high quality detergent oil rated with API service classification SG--SL. Select the oil's SAE viscosity grade according to your expected operating temperature. •_JUEVISCOSITY GRADES 'F -2O -._ -_ 0 -,o 30 ,32 o 4_ eo 1_ =o 0O ;o 100 4o 11 TEMPERATURIE RANGE ANTICIPATED BEFORE NEXT OtL CHANGE NOTE: Multi-viscosity oils (5W30, 10W30 etc.) improve starting in cold weather, and you should check your engine oil level frequently to avoid possible engine damage from running low on oil. Change the oil after every 25 hours of operation or at least once a year if the lawn mower is not used for 25 hours in one year. Check the crankcase oil level before starting the engine and after each five (5) hours of continuous use. Tighten oil plug securely each time you check the oil level. 9. Reconnect spark plug wire to plug. Oil fill cap / /_, \ _,,',,,LL _" dipstick _--_ \_ TO CHANGE AIR FILTER ENGINE OIL NOTE: Before tipping lawn mower to drain oil. empty fuel tank by running engine until fuel tank is empty. 1. Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug. 2. Remove engine oil cap; lay aside on a clean surface. 3. Tip lawn mower on its side as shown and drain oil into a suitable container. Rock lawn mower back and forth to remove any oil trapped inside of engine. mark-_'-'_ LowerJ mark \ _l,f-_,%-_,,,,,_ _//_ _ J _,0_,_,(_-N_'_' .'_ II II I Your engine will not run properly and may be damaged by using a dirty air filter. Replace the air filter every 100 hours of operation or every season, whichever occurs first. Service air cleaner more often under dusty conditions. TO CLEAN AIR FILTER 1. Remove cover. 2. Carefully remove cartridge. 3. Clean by gently tapping on a flat surA face. If very dirty, replace cartridge. CAUTION: Petroleum solvents, such as kerosene, are not to be used to clean cartridge. They may cause deterioration of the cartridge. Do not oil cartridge. Do not use pressurized air to clean or dry cartridge. 4. Install cartridge, then replace cover. Filter Filter Cover Tabs 4. Wipe off any spilled oil from lawn mower or side of engine. 5. Fill engine with oil. The engine oil capacity is 18.5 oz. If oil is not completely drained from engine, you may not need the entire container of a 20 oz, bottle of oil. Slowly pour 314 of the MUFFLER oil from the container down the oil fill spout into the engine. Inspect and replace corroded muffler as it 6. Wait one minute to allow oil to settle. could create a fire hazard and/or damage. Use guage on oil fill cap/dipstick for checking level. Insert dipstick into the SPARK PLUG tube and rest the oil fill cap on the tube. Replace spark plug at the beginning of DO NOT thread the cap into the tube each mowing season or after every 100 when taking reading. hours of operation, whichever occurs 7. Continue adding small amounts of first. Spark plug type and gap setting oil and rechecking the dipstick until it are shown in the "PRODUCT SPECIFICreads full. DO NOT overfill, or engine ATIONS" section of this manual. will smoke on startup. 8. Always be sure to retighten oil dipstick before starting engine. 12 CLEANING IMPORTANT: For best performance, keep mower housing free of built-up grass and trash. Clean the underside of your mower after each use. ACAUTION: Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug. • Clean the underside of your lawn mower by scraping to remove build-up of grass and trash. • Clean engine often to keep trash from accumulating. A clogged engine runs hotter and shortens engine life. • Keep finished surfaces and wheels free of all gasoline, oil, etc. • We do not recommend using a garden hose to clean lawn mower unless the electrical system, muffler, air filter and carburetor are covered to keep water out. Water in engine can result in shortened engine life. _WARNING: To avoid serious injury, before performing any service or adjustments: 1. Release control bar and stop engine. 2. Make sure the blade and all moving parts have completely stopped. 3. Disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug. LAWN MOWER TO ADJUST CUTTING HEIGHT See =TO ADJUST CUTTING HEIGHT" in the Operation section of this manual. SQUEEZE TO ADJUST Mowing ,-_ .,_. poe tion REAR DEFLECTOR The rear deflector, attached between the rear wheels of your mower, is provided to minimize the possibility that objects will be thrown out of the rear of the mower into the operator mowing position. If the deflector becomes damaged, it should be replaced. TO ADJUST I , I I I I I I ', '] • . Mowing _o_ / i / I I ,/ I i I / I l ! Mountingl _ LJlJ bracket -LU pin LOW POSITION HIGH POSITION HANDLE The handle can be mounted in a high or low position, The mounting holes in the bottom of lower handle are off center for raising or lowering the handle. 1. Remove upper handle and all wire tie(s) securing cable(s) to lower handle. 2. Remove hairpin cotters from lower handle bracket mounting pin. 3. Squeeze lower handle in to remove it from mounting pins. 4. Turn lower handle over to raise or lower handle. 5. Squeeze lower handle in and position holes onto mounting pins on handle bracket. 6. Reassemble upper handle and all parts removed from lower handle. ._ pos'don \ Lowe r ROTATE 13 ENGINE CARBURETOR Maintenance, repair, or replacement of the emission control devices and systems, which are being done at the customers expense, may be performed by any non-road engine repair establishment or individual. Warranty repairs must be performed by an authorized engine manufacturer's service outlet. Your carburetor is not adjustable. If your engine does not operate properly due to suspected carburetor problems, take your lawn mower to a Sears or other qualified service center for repair or adjustment. IMPORTANT: Never tamper with the engine governor, which is factory set for proper engine speed. Overspeeding the engine above the factory high speed setting can be dangerous. If you think the engine-governed high speed needs adjusting, contact a Sears or other qualified service center, which has proper equipment and experience to make any necessary adjustments. ENGINE SPEED Your engine speed has been factory set. Do not attempt to increase engine speed or it may result in personal injury. If you believe that the engine is running too fast or too slow, take your lawn mower to a Sears or other qualified service center for repair and adjustment. Immediately prepare your lawn mower for storage at the end of the season or if the unit will not be used for 30 days or more. SQUEEZE TO FOLD LAWN MOWER When lawn mower is to be stored for a period of time, clean it thoroughly, remove all dirt, grease, leaves, etc. Store in a clean, dry area. 1. Clean entire lawn mower (See "CLEANING" in the Maintenance section of this manual). 2. Lubricate as shown in the Maintenance section of this manual. 3. Be sure that all nuts, bolts, screws, and pins are securely fastened. Inspect moving parts for damage, breakage and wear. Replace if necessary. 4. Touch up all rusted or chipped paint surfaces; sand lightly before painting. HANDLE MOWING POSITION control bar FOLD FORWARD FOR You can fold your lawn mower handle for storage. 1. Squeeze the bottom ends of the lower handle toward each other until the lower handle clears the handle bracket, then move handle forward. 2. Loosen upper handle mounting bolts enough to allow upper handle to be folded back. IMPORTANT: When folding the handle for storage or transportation, be sure to fold the handle as shown or you may damage the control cables. • When setting up your handle from the storage position, the lower handle will automatically lock into the mowing position. Upper handle STORAGE Handle knob Lower handle ENGINE Maintenance, repair, or replacement of the emission control devices and systems, which are being done at the customers expense, may be performed by any non-road engine repair establishment or individual. Warranty repairs must be performed by an authorized engine manufacturer's service outlet. 14 FUEL SYSTEM IMPORTANT: It is important to prevent ENGINE OIL Drain oil (with engine warm) and replace with clean engine oil. (See "ENGINE" in the Maintenance section of this manual). gum deposits from forming in essential fuel system parts such as carburetor, fuel filter, fuel hose or tank during storage. Also, alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. • Empty the fuel tank by starting the engine and letting it run until the fuel lines and carburetor are empty. • Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur. • Use fresh fuel next season. NOTE: Fuel stabilizer is an acceptable alternative in minimizing the formation of fuel gum deposits during storage. Add stabilizer to gasoline in fuel tank or storage container. Always follow the mix ratio found on stabilizer container. Run engine at least 10 minutes after adding stabilizer to allow the stabilizer to reach the carburetor. Do not empty the gas tank and carburetor if using fuel stabilizer. CYLINDER 1. Remove spark plug. 2. Pour 29 ml of oil through spark plug hole into cylinder. 3. Pull starter handle slowly a few times to distribute oi1. 4. Replace with new spark plug. OTHER • Do not store gasoline from one season to another. • Replace your gasoline can if your can starts to rust. Rust and/or dirt in your gasoline will cause problems. • If possible, store your unit indoors and cover it to protect it from dust and dirt. • Cover your unit with a suitable protective cover that does not retain moisture. Do not use plastic. Plastic cannot breathe, which allows condensation to form and will cause your unit to rust. IMPORTANT: Never cover mower while engine and exhaust areas are still warm. _CAUTION: Never store the lawn mower with gasoline in the tank inside a building where fumes may reach an open flame or spark. Allow the engine to cool before storing in any enclosure. TROUBLESHOOTING - See appropriate to a Sears Parts & Repair Centre. PROBLEM CAUSE Does not start section in manual unless directed CORRECTION 1. Dirty air filter. 1. Clean/replace air filter. Out of fuel. 3. Stale fuel. Fill fuel tank. 3. Empty fuel tank and refill tank with fresh, clean gasoline. 4. Empty fuel tank and refill tank with fresh, clean gasoline. 5. Connect wire to plug. . . 4. Water in fuel. 5. Spark plug wire is disconnected. 6. Bad spark plug. 7. Loose blade or broken blade adapter. 8. Control bar in released position. 9. Control bar defective. 10. Fuel valve lever (if so equipped) in OFF position. 11 .Weak battery (if equipped). 12. Disconnected battery connector (if equipped). 15 6. Replace spark plug. 7. Tighten blade bolt or replace blade adapter. 8. Depress control bar to handle. 9. Replace control bar. 10. Turn fuel valve lever to the ON position. 11. Charge battery. 12. Connect battery to engine. TROUBLESHOOTING - See appropriate to a Sears Parts & Repair Centre, PROBLEM CAUSE LOSS of power Poor cut uneven section in manual unless directed 1. Rear of mower housing or blade dragging in grass. 2. Cutting too much grass. 3. Dirty air filter. 4. Buildup of grass, leaves, and trash under mower. 5. Too much oil in engine. 6. Walking speed too fast. 1. Raise cutting height. 1. Worn, bent or loose blade. 1. Replace blade. Tighten blade bolt. 2. Set all wheels at same height. 3. Clean underside of mower housing. 2. Wheel heights uneven. 3. Buildup of grass, leaves and trash under mower. Excessive vibration 1. Worn, bent or loose blade. 2. Bent engine crankshaft. Starter rope hard to pull CORRECTION . Engine flywheel brake is on when control bar is released. 2. Bent engine crankshaft. 3. Blade adapter broken. 4. Blade dragging in grass. 2. Raise cutting height. 3. Clean/replace air filter. 4. Clean underside of mower housing. 5. Check oil level. 6. Cut at slower walking speed. 1. Replace blade. Tighten blade bolt. 2. Contact a Sears or other qualified service center. 1. Depress control bar to upper handle before pulling the starter rope. 2. Contact a Sears or other qualified service center. 3. Replace blade adapter. 4. Move lawn mower to cut grass or to hard surface. Grass catcher not filling (If so equipped) 1. Cutting height too low. 2. Lift on blade worn off. 3. Catcher not venting air. 1. Raise cutting height. 2. Replace blade. 3. Clean grass catcher. Hard to push 1. Grass is too high or wheel height is too low. 2. Rear of mower housing or blade dragging in grass. 3. Grass catcher too full. 4. Handle height position not right for you. 1. Raise cutting height. 16 2. Raise rear of mower housing one (1) setting higher. 3. Empty grass catcher. 4. Adjust handle height to suit. SERVICE NOTES 17 CRAFTSMAN ROTARY LAWN MOWER - - MODEL NUMBER 944.365440 3 \ 143 dm_ 42 Iii 6 13 11 12 14 \ 7 23 5 15 5O 37 37 41 40 36 21 34 co j 52 18 t9 51 33 37 3O 28 37 48 36 32 26 10 36 20 45 j_ CRAFTSMAN ¢JO ROTARY LAWN MOWER - - MODEL NUMBER KEY PART NO. NO. DESCRIPTION 1 2 3 4 5 6 7 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Control Bar Upper Handle Lower Handle Rope Guide Nut, Hex Handle Bolt Wire Tie Hinge Bracket Mulcher Door Engine Zone Control Cable Hex Washer Head Screw Up-Stop Bracket Handle Knob Hairpin Cotter Support Bracket Screw 1/4-20 x 3/8 Axle Arm Assembly, LF Axle Arm Assembly, RF Rear Skirt Selector Spring, Front Kit, Rear Door (Includes Springs) Locknut, Hex 5/16-18 Handle Bracket Assembly, LH Handle Bracket Assembly, RH Screw Hinge Spring Wheel Adjusting Bracket, Front Spacer Discharge Deflector Selector Spring, Rear Selector Knob 194177X428 194179X479 169708X479 179585 132004 191574 66426 154132 165754 176556 750634 86899)(004 189713X428 51793 165946X479 851856 186577X004 186578X004 188987 168360X004 186612 73930500 166111X479 166112X479 17600406 152124 160835X007 183901 165760 169421X004 701037 KEY PART NO. NO, 34 36 37 39 40 41 42 43 44 45 46 48 50 51 52 186576X004 160828 193851X460 83923 188813 88652 165766 165767 184193 150406 107339X 186575X004 196076 147286 190490 53 54 55 56 57 59 851084 850263 851074 189028 184590 --- 62 67 - - - - 73800400 192770 162300 196069 196071 944.364490 DESCRIPTION Axle Arm Assembly,LR ShoulderBolt 5/16-18 Wheel & Tire Assembly FlangedLecknut Frame,Grassbag Hinge Screw Spring,LH Spring,RH Bolt,Rear Door Screw,Hex Head,Threaded, Rolled 3/8-16 x 1 Danger Decal Axle Arm Assembly,RR Gressbag Hinge Rod Kit,Lawn Mower HousingAssembly (IncludesKeyNumbers 17, 18 and 46) Screw,Hex Head, Grade 8 3/8-24x 1-3/8 HelicalLockwasher HardenedWasher 21" Blade BladeAdapter Engine,Honda,Model Number GCV160-AS3A (See Breakdown) Locknut,Hex 1/4-20 Clip, Cable Warning Decal (not shown) Owner's Manual, English Owner'sManual, French NOTE: All component dimensions 1 inch = 25.4 mm given in U.S. inches. IMPORTANT: Use onlyOriginal Equipment Manufacturer(O.E.M.) replacementparts. Failureto do so couldbe hazardous,damage your lawn mower and voidyourwarranty. HONDA 4-CYCLE LABEL ENGINE MODEL NUMBER J CHOKE GCV-160-AS3A !.__ _---lo FAN COVER I :) I CAMSHAFT PULLEY 7 $ 12 |0 2 12 4 13---4D 2 14 _3 CARBURETOR AIR CLEANER I I RECOIL STARTER J 2O HONDA 4-CYCLE ENGINE MODEL NUMBER LABELS CAMSHAFT KEY NO. PART NO. DESCRIPTION 9 7400187 Mark, Choke Indication CHOKE KEY PART NO, NO, DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 Seal, Choke Lever Spring, Cable Return Lever,Choke Base Comp.,Choke Spring, Choke Lever Hook, ChokeSpring Plate, Choke Rod, Stop Bolt,Flange #6 x 16 Screw,Tapping #4 x 8 (PO) Screw,Pan Head #5 x 19 Screw, Pan Head #4 x 8 Nut, Flange 5 mm 7257157 4209581 7257165 7257173 7257181 7257199 7257207 7229867 0747733 3674413 2544690 0369017 0636951 DESCRIPTION 1 2 3 4 5 6 8 9 10 11 12 13 14 RubberSupporter(107 mm) Cock Assembly,Fuel Bracket,Fuel Cock Cap Assembly,Fuel Tank Tube, Fuel CoverComp., Fan (T89) Collar,Fuel Cock Bolt,Stud Screw,WasherHead #5 x 10 Tube, FuelTank Clip,Tube (B8) Clip,Tube (1310) Clip,Tube (C9) 3683646 7357379 5189352 6673289 5580469 7399371 6978399 5581004 0671636 6754279 0250647 0250985 0053447 DESCRIPTION 1 8 9 11 Starter Assembly,Recoil Grip, Starter Rope, RecoilStarter Nut, Flange 6 mm 6092886 5580634 5580642 6478812 KEY PART NO. NO, DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PulleyComp.,Camshaft Shaft, Cam Pulley Belt,Timing(84HU7 G200) RockerArm, IntakeValve RockerArm, ExhaustValve Shaft, RockerArm Valve, Intake Valve, Exhaust Spring,Valve Retainer,IntakeValveSpring Screw,TappetAdjusting Nut,TappetAdjusting ORing 6.8 x 1.9 (ARAI) Seal, ValveStem 7049679 5580063 7058985 5580089 5580097 5580105 5580113 5580121 5580139 1426980 0294819 0004598 6315873 6839831 KEY PART NO. NO, 1 2 3 5 7 8 9 10 11 12 13 14 15 16 17 3088416 5580162 3465879 1441518 7301138 5580212 5580220 5580238 5580246 4581120 5580253 5580535 0639419 0635474 0635482 0636126 1672187 DESCRIPTION PackingSet FloatSet Chamber Set, Roat ScrewSet CarburetorAsssembly(BB62G A) Valve, Float Nozzle, Main Insulator,Carburetor Packing,Insulator Packing,Carburetor Packing,Carburetor GuideComp., Air Screw,Pan Head #5 x 6 Jet, Main #60 Jet, Main #62 Jet, Main #65 ScrewSet, Drain AIR CLEANER RECOIL STARTER KEY PART NO. NO. PULLEY CARBURETOR FAN COVER KEY PART NO. NO. GCV-160-AS3A 21 KEY PART NO. NO. DESCRIPTION 1 2 3 5 6 7 8 Tube, Breather Element, AirCleaner Case Assembly,Air Cleaner Packing,Air Cleaner Cover,Air Cleaner Bolt, Flange #6 x 86 (CT200) Bolt, Flange #6x 14 5720289 6718159 5580410 5664560 6673255 5580964 2374742 HONDA 4-CYCLE CYLINDER BARREL CRANKSHAFT J ENGINE MODEL NUMBER J GCV-160-AS3A PISTON CONNECTING ROD J OIL PAN] I MUFFLER ? J 22 FLYWHEEL HONDA 4-CYCLE ENGINE FLYWHEEL PART NO. DESCRIPTION 1 3 4 5 6 8 10 11 12 13 15 16 19 20 21 0348433 6859722 6859714 6315816 5580683 5580790 0803619 1725050 0671552 0442038 0485946 1510361 1824630 1240845 7301591 Key, Special,Woodruff #25 x 18 Coil Assembly,Ignition FlywheelAssembly Cord, Stop Switch SwitchAssembly, EngineStop Spring, Brake Lever Bolt,Flange #6 x 14 (CT200) Bolt,Flange #6 x 23 (CT200) Bolt,Flange #6 x 20 (CT200) Nut, Special 14 mm Screw,WasherHead #4x12 Washer, Plain 4 mm Clip A, Cable GrommetA, Rear Cover Brake Sub-Assembly BARREL KEY PART NO. NO. DESCRIPTION 1 2 3 4 5 6 7 8 9 Barrel Assembly, Cylinder Clip, Valve Guide Cover, Head Cover Comp., Breather Bolt, Flange #6 x 12 (CT200) Bolt, Flange #6 x 14 (CT200) Oil Seal 25A x 62 x 6 Plug, Spark (BPR6ES) (NGK) Guide, Exhaust Valve (O.S.) 6842413 2399780 5579990 5580006 0636845 0803619 5581038 1441112 1899848 GCV-160-AS3A CRANKSHAFT KEY NO. CYLINDER MODEL NUMBER KEY NO. PART NO. DESCRIPTION 3 5 5664495 5581012 Crankshaft Comp. Washer, Thrust OIL PAN KEY NO. PART NO. DESCRIPTION 1 2 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 6771489 5716915 1452754 5664503 5664511 6384341 6384333 5580287 5580295 1427244 1427251 5580303 0803619 0748111 2413862 2456697 5581046 1377704 0345900 0115527 1417369 Pan Assembly,Oil Gauge Assembly,Oil Level Packing,Oil Fillercap Extension,Oil Filler Washer, ExtensionRock ShaftComp., GovernorHolder GovernorAssembly Weight,Governor Holder,GovernorWeight Pin,GovernorWeight Slider,Governor Shaft, GovernorArm Bolt,Flange #6 x 14 (CT200) Bolt,Flange #6 x 25 Washer,Thrust 6 mm Clip,GovernorHolder Oil Seal 28 x 41.25 x 6 ORing 14.8 x 2.4 (NOK) Washer, Plain 6 mm Pin, Lock 8 mm DowelPin #8 x 20 MUFFLER PISTON / CONNECTING ROD KEY PART NO. NO. 1 2 3 4 5 6 5580014 1426576 5580022 1431055 2605517 5655949 7154727 KEY NO. PART NO. DESCRIPTION 1 2 3 4 5 6 7 8 5580485 5664610 5737457 5580972 0636845 5656012 5611397 1431121 Muffler,Complete Protector, Muffler(CBU) Gasket,Muffler Bolt,Flange #6 x 79 (CT200) Bolt,Flange #6 x 12 (CT200) Spark Arraster Plate, ArrssterNumber Screw,Tapping #4 x 6 DESCRIPTION Piston Pin, Piston Rod Assembly,Connecting Bolt, Connecting Rod Clip,PistonPin 13 mm RingSet, Piston(Riken) Ring Set, Piston(Teikoku) 23 Just Call: 1-800-4-MY-HOME ® (1-800-469-4663) 24 hours a day, 7 days a week Fortherepairof majorbrand appliancesin your own home... no matterwhomadeit,no matterwho soldit! For your nearest Sears Parts and Service IocaUon, to bring in products likevacuums, lawn equipmentand electronics. For Sears Parts & Service, to orderthe replacementparts, accessoriesand owner'smanuals that you need to do-it-yourseff. }',a N i{{ s _ www.sear$.ca To purchaseor inquireabouta Sears MaintenanceAgreement, call: 1-800-361-6665 9 a.m.-11 p.m. Mon. - Fri.,EST, 9 a.m. - 4 p.m. Sat. Pour serviceen fl'ang_s: 1-800-LE-FOYER _c (1-800-533-6937) www,eear_,ca ®/'ru Trademarks of Seam, Roebuck end Co. used under license by Sears Canada M_Marque d6posde / MCMarque de commerce de Seam, Roebuck and Co. utllis6e en ve_u d'une Iioence de Sears Canada 196069 12.06.04 BY Printed in U.S.A.